Contact tip and receiving assembly of a welding torch

ABSTRACT

A welding torch system includes a receiving assembly to receive a contact tip and a welding nozzle. The welding torch system also includes a locking element that retains the contact tip in a partially secure position. Further, the welding torch system includes the welding nozzle configured to couple to the receiving assembly to retain the contact tip in a fully secure position.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Non-provisional U.S. Patent Application of U.S.Provisional Application No. 62/220,732, entitled “Contact Tip andReceiving Assembly of a Welding Torch,” filed Sep. 18, 2015, which ishereby incorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure relates generally to welding systems and, moreparticularly, to securement of contact tips in welding torches ofwelding systems.

Welding is a process that has increasingly become ubiquitous in variousindustries and applications. Additionally, as welding has increased ingeneral, automated welding processes are also becoming increasinglypopular. With increasing automation in the field of welding, simpledesigns to meet automation maintenance goals are ever more valuable. Forexample, automation complexity may decrease as maintenance complexity ofthe welding systems also decreases.

Therefore, it may be advantageous to provide a mechanism that simplifiesreplacement and securement of components within welding systems that arefrequently replaced. The present subject matter provides a mechanism forreplacement and securement of contact tips within a welding systemwithout the use of tools.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimedsubject matter are summarized below. These embodiments are not intendedto limit the scope of the claimed subject matter, but rather theseembodiments are intended only to provide a brief summary of possibleforms of the subject matter. Indeed, the subject matter may encompass avariety of forms that may be similar to or different from theembodiments set forth below.

In a first embodiment, a method to secure a contact tip in a weldingsystem may include applying an axial force on the contact tip toward areceiving assembly of a welding torch to establish a partially securecoupling of the contact tip to the receiving assembly. Additionally, themethod may include securing a welding nozzle to the receiving assemblyto establish a fully secure coupling of the contact tip to the receivingassembly.

In another embodiment, a welding torch system may include a receivingassembly that receives a contact tip and a welding nozzle. Additionally,the welding torch system may include a locking element that retains thecontact tip in a partially secure position. Further, the welding nozzlemay couple to the receiving assembly to retain the contact tip in afully secure position.

In another embodiment, a torch system may include a contact tip thatmounts without tools within a receiving assembly mounted on a weldingtorch. Additionally, the contact tip transitions between a fully securedposition and a partially secured position within the receiving assembly.The contact tip may include an elongated hollow body made from anelectrically conductive material. Further, the elongated hollow bodyinteracts with a locking element of the receiving assembly.

In another embodiment, a receiving assembly includes an inner bore thatreceives a contact tip. Additionally, the receiving assembly includes alocking element that interacts with the contact tip to maintain thecontact tip in a partially secure position. The receiving assembly alsoincludes a first coupling interface that couples to a neck of a weldingtorch, and a second coupling interface that couples to a welding nozzleto maintain the contact tip in a fully secure position.

In another embodiment, a contact tip receiving assembly includes aninner bore configured to receive a contact tip. The inner bore includesat least one cooling channel disposed along an axial length of the innerbore and a contact tip securement mechanism that secures the contact tipwithin the receiving assembly. Additionally, the contact tip receivingassembly includes at least one gas-through port that receives shieldinggas from the at least one cooling channel. Further, the at least onegas-through port directs the shielding gas radially away from the innerbore. Furthermore, the at least one cooling channel provides a path forthe shielding gas to flow in direct contact with at least a portion ofthe contact tip disposed within the inner bore.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is an embodiment of a metal inert gas (MIG) welding system with apower source and a wire feeder, in accordance with an embodiment;

FIG. 2 is a side view of an embodiment of a welding torch of the MIGwelding system of FIG. 1, in accordance with an embodiment;

FIG. 3 is an exploded view of a portion of the welding torch of FIG. 2,in accordance with an embodiment;

FIG. 4 is a further exploded view of the portion of the welding torch ofFIG. 3, in accordance with an embodiment;

FIG. 5 is a cross-sectional illustration of the portion of the weldingtorch of FIG. 3, in accordance with an embodiment;

FIG. 6 is a cross-sectional illustration of a magnified portion of thewelding torch of FIG. 5, in accordance with an embodiment;

FIG. 7 is a flow diagram of a method to install a contact tip within thewelding torch in a fully secure position, in accordance with anembodiment;

FIG. 8 is a perspective view of the welding torch of FIG. 3 with an endportion of a receiving assembly removed, in accordance with anembodiment;

FIG. 9 is a cross-sectional illustration of the contact tip and thereceiving assembly of FIG. 8, in accordance with an embodiment;

FIG. 10 is a cross-sectional illustration of a portion of the weldingtorch of FIG. 3, in accordance with an embodiment;

FIG. 11 is a front perspective view of a design for a contact tip havinga retention groove, in accordance with an embodiment;

FIG. 12 is a rear perspective view of a design for the contact tip ofFIG. 11, in accordance with an embodiment;

FIG. 13 is a first side view of a design for the contact tip of FIG. 11,in accordance with an embodiment;

FIG. 14 is a second side view of a design for the contact tip of FIG.11, in accordance with an embodiment;

FIG. 15 is a top view of a design for the contact tip of FIG. 11, inaccordance with an embodiment;

FIG. 16 is a bottom view of a design for the contact tip of FIG. 11, inaccordance with an embodiment;

FIG. 17 is a front view of a design for the contact tip of FIG. 11, inaccordance with an embodiment;

FIG. 18 is a rear view of a design for the contact tip of FIG. 11, inaccordance with an embodiment;

FIG. 19 is a cross-sectional cutaway view of a design for the contacttip of FIG. 11, in accordance with an embodiment;

FIG. 20 is a front perspective view of a design for a contact tip havingone or more discrete recesses, in accordance with an embodiment;

FIG. 21 is a rear perspective view of a design for the contact tip ofFIG. 20, in accordance with an embodiment;

FIG. 22 is a first side view of a design for the contact tip of FIG. 20,in accordance with an embodiment;

FIG. 23 is a second side view of a design for the contact tip of FIG.20, in accordance with an embodiment;

FIG. 24 is a top view of a design for the contact tip of FIG. 20, inaccordance with an embodiment;

FIG. 25 is a bottom view of a design for the contact tip of FIG. 20, inaccordance with an embodiment;

FIG. 26 is a front view of a design for the contact tip of FIG. 20, inaccordance with an embodiment;

FIG. 27 is a rear view of a design for the contact tip of FIG. 20, inaccordance with an embodiment;

FIG. 28 is a cross-sectional cutaway view of a design for the contacttip of FIG. 20, in accordance with an embodiment;

FIG. 29 is a front perspective view of a design for a contact tip nothaving a retention groove, in accordance with an embodiment;

FIG. 30 is a rear perspective view of a design for the contact tip ofFIG. 29, in accordance with an embodiment;

FIG. 31 is a first side view of a design for the contact tip of FIG. 29,in accordance with an embodiment;

FIG. 32 is a second side view of a design for the contact tip of FIG.29, in accordance with an embodiment;

FIG. 33 is a top view of a design for the contact tip of FIG. 29, inaccordance with an embodiment;

FIG. 34 is a bottom view of a design for the contact tip of FIG. 29, inaccordance with an embodiment;

FIG. 35 is a front view of a design for the contact tip of FIG. 29, inaccordance with an embodiment;

FIG. 36 is a rear view of a design for the contact tip of FIG. 29, inaccordance with an embodiment;

FIG. 37 is a cross-sectional cutaway view of a design for the contacttip of FIG. 29, in accordance with an embodiment;

FIG. 38 is a front-side perspective view of a design for a weldingnozzle, in accordance with an embodiment;

FIG. 39 is a rear-side perspective view of a design for the weldingnozzle of FIG. 38, in accordance with an embodiment;

FIG. 40 is a front perspective view of a design for the welding nozzleof FIG. 38, in accordance with an embodiment;

FIG. 41 is a rear perspective view of a design for the welding nozzle ofFIG. 38, in accordance with an embodiment;

FIG. 42 is a first side view of a design for the welding nozzle of FIG.38, in accordance with an embodiment;

FIG. 43 is a second side view of a design for the welding nozzle of FIG.38, in accordance with an embodiment;

FIG. 44 is a top view of a design for the welding nozzle of FIG. 38, inaccordance with an embodiment;

FIG. 45 is a bottom view of a design for the welding nozzle of FIG. 38,in accordance with an embodiment;

FIG. 46 is a front view of a design for the welding nozzle of FIG. 38,in accordance with an embodiment;

FIG. 47 is a rear view of a design for the welding nozzle of FIG. 38, inaccordance with an embodiment;

FIG. 48 is a cross-sectional cutaway view of a design for the weldingnozzle of FIG. 38, in accordance with an embodiment; and

FIG. 49 is an exploded view of a design for various components of thewelding nozzle of FIG. 38, in accordance with an embodiment.

DETAILED DESCRIPTION

One or more embodiments of the present disclosure will be describedbelow. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions are made toachieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

Turning now to the drawings, and referring first to FIG. 1, a weldingsystem 10 is illustrated as including a power source 12 coupled to awire feeder 14. In the illustrated embodiment, the power source 12 isseparate from the wire feeder 14, such that the wire feeder 14 may bepositioned at some distance from the power source 12 near a weldinglocation. However, it should be understood that the wire feeder 14, insome implementations, may be integral with the power source 12. Thepower source 12 may supply weld power to a torch 16 through the wirefeeder 14, or the power source 12 may supply weld power directly to thetorch 16. The wire feeder 14 supplies a wire electrode 18 (e.g., solidwire, cored wire, coated wire) to the torch 16. A gas supply 20, whichmay be integral with or separate from the power source 12, supplies agas (e.g., CO₂, argon) to the torch 16. An operator may engage a trigger22 of the torch 16 to initiate an arc 24 between the electrode 18 and awork piece 26. In some embodiments, the welding system 10 may betriggered by an automation interface including, but not limited to, aprogrammable logic controller (PLC) or robot controller. The weldingsystem 10 is designed to provide welding wire (e.g., electrode 18), weldpower, and shielding gas to the welding torch 16. As will be appreciatedby those skilled in the art, the welding torch 16 may be of manydifferent types, and may facilitate use of various combinations ofelectrodes 18 and gases.

The welding system 10 may receive data settings from the operator via anoperator interface 28 provided on the power source 12. The operatorinterface 28 may be incorporated into a faceplate of the power source12, and may allow for selection of settings such as the weld process(e.g., stick, TIG, MIG), the type of electrode 18 to be used, voltageand current settings, transfer mode (e.g., short circuit, pulse, spray,pulse), and so forth. In particular, the welding system 10 allows forMIG welding (e.g., pulsed MIG welding) with electrodes 18 (e.g., weldingwires) of various materials, such as steel or aluminum, to be channeledthrough the torch 16. The weld settings are communicated to controlcircuitry 30 within the power source 12.

The control circuitry 30 operates to control generation of welding poweroutput that is applied to the electrode 18 by power conversion circuitry32 for carrying out the desired welding operation. In some embodiments,the control circuitry 30 may be adapted to regulate a pulsed MIG weldingregime that may have aspects of short circuit transfer and/or of spraytransfer of molten metal from the welding wire to a molten weld pool ofa progressing weld. Such transfer modes may be controlled duringoperation by adjusting operating parameters of current and voltagepulses for arcs 24 developed between the electrode 18 and the work piece26.

The control circuitry 30 is coupled to the power conversion circuitry32, which supplies the weld power (e.g., pulsed waveform) that isapplied to the electrode 18 at the torch 16. The power conversioncircuitry 32 is coupled to a source of electrical power as indicated byarrow 34. The power applied to the power conversion circuitry 32 mayoriginate in the power grid, although other sources of power may also beused, such as power generated by an engine-driven generator, batteries,fuel cells or other alternative sources. Components of the powerconversion circuitry 32 may include choppers, boost converters, buckconverters, inverters, and so forth.

The control circuitry 30 controls the current and/or the voltage of theweld power supplied to the torch 16. The control circuitry 30 maymonitor the current and/or voltage of the arc 24 based at least in parton one or more sensors 36 within the wire feeder 14 or torch 16. In someembodiments, a processor 35 of the control circuitry 30 determinesand/or controls the arc length or electrode extension based at least inpart on feedback from the sensors 36. The arc length is defined hereinas the length of the arc between the electrode 18 and the work piece 26.The processor 35 determines and/or controls the arc length or electrodeextension utilizing data (e.g., algorithms, instructions, operatingpoints) stored in a memory 37. The data stored in the memory 37 may bereceived via the operator interface 28, a network connection, orpreloaded prior to assembly of the control circuitry 30. Operation ofthe power source 12 may be controlled in one or more modes, such as aconstant voltage (CV) regulation mode in which the control circuitry 30controls the weld voltage to be substantially constant while varying theweld current during a welding operation. That is, the weld current maybe based at least in part on the weld voltage. Additionally, or in thealternative, the power source 12 may be controlled in a current controlmode in which the weld current is controlled independent of the weldvoltage. In some embodiments, the power source 12 is controlled tooperate in a constant current (CC) mode where the control circuitry 30controls the weld current to be substantially constant while varying theweld voltage during a welding operation.

FIG. 2 illustrates an embodiment of the torch 16 of FIG. 1. As discussedin relation to FIG. 1, the torch 16 includes the trigger 22 forinitiating a weld and supplying the electrode 18 to the weld.Specifically, the trigger 22 is disposed on a handle 38. A weldingoperator holds the handle 38 when performing a weld. At a first end 40,the handle 38 is coupled to a cable 42 where welding consumables (e.g.,the electrode, the shielding gas, and so forth) are supplied to theweld. Welding consumables generally travel through the handle 38 andexit at a second end 44, which is disposed on the handle 38 at an endopposite from the first end 40.

The torch 16 includes a neck 46 extending out of the second end 44 ofthe handle 38. As such, the neck 46 is coupled between the handle 38 anda welding nozzle 48. As should be noted, when the trigger 22 is pressedor actuated, welding wire (e.g., electrode 18) travels through the cable42, the handle 38, the neck 46, and the welding nozzle 48, so that thewelding wire extends out of an end 50 (i.e., torch tip) of the weldingnozzle 48. Further, as illustrated in FIG. 2, the handle 38 is securedto the neck 46 via fasteners 52 and 54, and to the cable 42 viafasteners 52 and 54. The welding nozzle 48 is illustrated with a portionof the welding nozzle 48 removed to show the electrode 18 extending outof a contact tip 56 that is disposed within the welding nozzle 48. FIGS.38-49 illustrate various views of a design for the welding nozzle 48described herein.

FIG. 3 is an exploded view of a portion of the welding torch 16.Included in this illustration is a receiving assembly 58. The receivingassembly 58 receives the contact tip 56 during replacement of thecontact tip 56, facilitates mechanical coupling to the welding torch 16for the contact tip 56, and facilitates electrical coupling to the powersource 12 for the contact tip 56, as discussed in detail below.Additionally, the welding nozzle 48 couples to the welding torch 16 at acoupling interface 60 of the receiving assembly 58. The couplinginterface 60 may include threads corresponding to threads on an interiorof the welding nozzle 48. The threads of the coupling interface 60 mayfacilitate securement of the welding nozzle 48 to the welding torch 16and around the receiving assembly 58.

Furthermore, the receiving assembly 58 may include gas-through ports 62to facilitate movement of shielding gas to a welding site. The receivingassembly 58 may also include a retention device 64. With the weldingnozzle 48 uncoupled from the receiving assembly 58, application of anaxial force to the contact tip 56 in an axial direction 66 may urge thecontact tip 56 into the receiving assembly 58. Upon insertion, theretention device 64 may interact with a retention groove 68 of thecontact tip 56 to provide a partially secure coupling of the contact tip56 to the welding torch 16. It may be appreciated that the retentiongroove 68 is depicted as substantially constant around an entirecircumference of the contact tip 56. Accordingly, the contact tip 56 maybe inserted into the receiving assembly 58 with any angular orientation(e.g., rotated at any angle about a central axis of the contact tip 56and the receiving assembly 58, for example, corresponding to the axialdirection 66). FIGS. 11-19 illustrate various views of a design for thecontact tip 56 having the substantially constant retention groove 68around the entire circumference of the contact tip 56, as describedherein.

However, in other contemplated embodiments, the retention groove 68 mayextend only partially around the circumference of the contact tip 56 toreceive a portion of the retention device 64 when the contact tip 56 isin a specific orientation (e.g., rotated at a specific angle or range ofangles about a central axis of the contact tip 56 and the receivingassembly 58, for example, corresponding to the axial direction 66)within the receiving assembly 58. Further, in certain embodiments, theretention groove 68 may be replaced by one or more discrete recesses 67circumferentially surrounding the contact tip 56 corresponding to ashape of the retention device 64 such that the contact tip 56 may bepositioned within the receiving assembly 58 in a number of discreteorientations (e.g., rotated at any one of a number of discrete anglesabout a central axis of the contact tip 56 and the receiving assembly58, for example, corresponding to the axial direction 66). FIGS. 20-28illustrate various views of a design for the contact tip 56 having theone or more discrete recesses 67 disposed around the entirecircumference of the contact tip 56, as described herein. Additionally,in certain embodiments, the contact tip 56 may not include the retentiongroove 68, and the retention device 64 may interact directly on a bodyof the contact tip 56 (e.g., by applying a radially inward force). FIGS.29-37 illustrate various views of a design for the contact tip 56without the retention groove 68 around the entire circumference of thecontact tip 56, as described herein. Furthermore, it may be appreciatedthat, in certain embodiments, the retention device 64 may include anyretention device capable of interacting with the retention groove 68 orthe body of the contact tip 56 to partially retain the contact tip 56.For example, the retention device 64 may include a ball that partiallysits within the retention groove 68 (or within one of the discreterecesses 67) while the contact tip 56 is positioned within the receivingassembly 58. Similarly, the ball may sit against the body of the contacttip 56 while the contact tip 56 is positioned within the receivingassembly 58. Alternatively, in certain embodiments, the retention device64 may include a pin with rounded ends that interacts in a similarmanner with the contact tip 56 as the ball described above. Any otherdevices capable of interacting with the contact tip 56 to partiallyretain the contact tip 56 are also contemplated as the retention device64.

Similarly, when the welding nozzle 48 is removed from the receivingassembly 58, an axial force on the contact tip 56 in a directionopposite the axial direction 66 may mechanically release the contact tip56 from the receiving assembly 58. Accordingly, after removal of thewelding nozzle 48 from the welding torch 16, the contact tip 56 may bemechanically released from the receiving assembly 58 without the aid oftools. Additionally, once the contact tip 56 is removed from thereceiving assembly 58 and the welding nozzle 48 is removed from thereceiving assembly 58, a new contact tip 56 may be mechanically coupled,in a partially secure manner, within the receiving assembly 58.

FIG. 4 is a further exploded view of the portion of the welding torch 16illustrated in FIG. 3. The exploded view of FIG. 4 provides additionaldetail into mechanics of the receiving assembly 58 that secures thecontact tip 56. For example, a locking element 69 (e.g., a locking beador ball) is illustrated. The locking element 69 interacts with theretention groove 68 in the contact tip 56. When the contact tip 56 is ina partially secured position (i.e., when the contact tip 56 is in thereceiving assembly 58 and the welding nozzle 48 is removed from thereceiving assembly 58), the locking element 69 is partially deposited inthe retention groove 68 of the contact tip 56. While in the retentiongroove 68, the locking element 69 may be held in place by a retentionband 70 to provide a radially inward force on the locking element 69into the retention groove 68. The radially inward force provided by theretention band 70 on the locking element 69 may establish a partiallysecure coupling of the contact tip 56 to the receiving assembly 58. Thepartially secure coupling may indicate a state in which the contact tip56 is affixed to the welding torch 16, but the contact tip 56 may nothave enough retention force for a welding operation. Accordingly, whenthe contact tip 56 is partially secured within the welding torch 16, thecontact tip 56 is easily removable from the welding torch 16. Forexample, the contact tip 56 may be toollessly removed from the weldingtorch 16 while the contact tip 56 is partially secured. Further, whilethe contact tip 56 is partially secured, a retention force provided bythe retention band 70 on the locking element 69 may not be sufficientfor the contact tip 56 to generate a sufficient electrical coupling withthe welding torch 16 to conduct a welding operation.

With the foregoing in mind, the contact tip 56 may become fully securewhen the welding nozzle 48 is coupled to the receiving assembly 58. Asdiscussed above, the receiving assembly 58 includes the couplinginterface 60. The coupling interface 60 may include male threads thatinteract with female threads within the welding nozzle 48 (not shown).The interaction between the coupling interface 60 and the welding nozzle48 may provide an additional force on the locking element 69 toestablish a fully secure coupling between the contact tip 56 and thereceiving assembly 58. The fully secure coupling may provide asufficient mechanical and electrical coupling between the contact tip 56and the receiving assembly 58 to conduct a welding operation.Accordingly, the contact tip 56 maintains mechanical and electricalcoupling with the receiving assembly 58 throughout the course of thewelding operation.

Further, if the contact tip 56 is in a fully secure state with thewelding nozzle 48 coupled to the receiving assembly 58, then removingthe welding nozzle 48 will function to transition the contact tip 56into a partially secure state. Therefore, to provide a mechanicalrelease and electrical decoupling of the contact tip 56 from the weldingtorch 16, the welding nozzle 48 is first removed from the receivingassembly 58. After removing the welding nozzle 48, the contact tip 56 isremoved by application of an axial force in the direction opposite theaxial direction 66. As mentioned above, this entire process may beaccomplished toollessly.

Additionally, the receiving assembly 58 includes a radial orifice 72 toaccept the locking element 69. A combination of the radial orifice 72and the locking element 69 may constitute the retention device 64intended to retain the contact tip 56 within the receiving assembly 58.The radial orifice 72 may be configured to intersect with an inner bore74 of the receiving assembly 58, which receives the contact tip 56.Additionally, the radial orifice 72 may include varying dimensions alonga radial length into the receiving assembly 58. In this manner, theradial orifice 72 may accept the locking element 69, and the varyingdimensions may enable the locking element 69 to move freely along anaxis of the radial orifice 72. Further, the radial orifice 72 may alsobe shaped such that a portion of the locking element 69 extends into theinner bore 74 when the locking element 69 is positioned in a deepestportion of the radial orifice 72. At the same time, the radial orifice72 may also be shaped in such a manner that the locking element 69cannot extend completely into the inner bore 74.

Moreover, the receiving assembly 58 may include a retention groove 76about a circumference of the receiving assembly 58. The retention groove76 may be sized such that it accepts and retains the retention band 70.As illustrated, in certain embodiments, the retention band 70 is anon-continuous ring that is expandable radially to fit around thereceiving assembly 58 within the retention groove 76. The receivingassembly 58 and the retention band 70 may include features thatmechanically interact to prevent the retention band 70 from rotatingabout the circumference of the receiving assembly 58. For example, theretention band 70 may include a bend or bends along a length of theretention band 70 that correspond with wider portions in sections of theretention groove 76. The bends of the retention band 70 and thecorresponding sections of the retention groove 76 mechanically interactto prevent the retention band 70 from rotating circumferentially aboutthe receiving assembly 58. In this manner, the retention band 70 mayremain radially or axially moveable within the constraints of theretention groove 76. Accordingly, when the locking element 69 is withinthe radial orifice 72 and the retention band 70 is within the retentiongroove 76, the retention band 70 at least partially covers the lockingelement 69 to retain the locking element 69 within the radial orifice72.

As the contact tip 56 is axially inserted into the inner bore 74 of thereceiving assembly 58, the contact tip 56 may come into contact with aportion of the locking element 69 that protrudes (e.g., radially inward)from the radial orifice 72 into the inner bore 74. The contact tip 56may include an angled surface on an end 78 of the contact tip 56 thaturges the locking element 69 to push radially outward against theretention band 70 and away from the contact tip 56. At the same time,the contact tip 56 may be urged against by a resistive force acting onthe locking element 69 from the retention band 70. During insertion ofthe contact tip 56 into the inner bore 74, the retention band 70 mayextend radially outward until the locking element 69 reaches theretention groove 68 of the contact tip 56. Upon reaching the retentiongroove 68, the locking element 69 is forced back toward the contact tip56 by the resistive force of the retention band 70. At this point, thecontact tip 56 may be considered mounted within the welding torch 16 ina partially secure manner. Further, the locking element 69 and theretention groove 68 may align in such a manner that the locking element69 reaches the retention groove 68 upon the contact tip 56 reaching afully inserted position within the inner bore 74. While less force maybe exerted on the locking element 69 by the retention band 70 when thelocking element 69 is deposited within the retention groove 68, theretention band 70 may maintain some force on the locking element 69 tomaintain the locking element 69 within the retention groove 68 and tohold the contact tip 56 against the wall of the inner bore 74 oppositethe locking element 69. Furthermore, the locking element 69 may rest incontact with a bottom surface of the retention groove 68, side surfacesof the retention groove 68, or all three of the surfaces of theretention groove 68.

Additionally, in certain embodiments, the end 78 of the contact tip 56may have a diameter D1 within a range between approximately 0.265 inchesand approximately 0.275 inches. The diameter D1 may be approximately 98percent of the size of a diameter D2 of the inner bore 74. In thismanner, the inner bore 74 may receive the contact tip 56 with minimalresistance while providing an appropriate fit to enable partialsecurement of the contact tip 56 within the receiving assembly 58.

In the partially secure state described above, axial movement of thecontact tip 56 within the receiving assembly 58 may be hindered, but notprevented. Accordingly, the contact tip 56 may still be removed viaaxial force applied in a direction away from the receiving assembly 58.Force provided without the use of tools may be sufficient for removal ofthe contact tip 56 from the receiving assembly 58. Further, electricalcoupling of the contact tip 56 to the welding torch 16 may beestablished in the partially secure state, but the electrical couplingmay not be sufficient for current transfer during normal weldingoperations.

FIG. 5 is a cross-sectional illustration of a portion of the weldingtorch 16 when the contact tip 56 is in a fully secure position. Asillustrated, shielding gas, wire (i.e., the electrode 18), and currentflow through the welding torch 16 in a direction 80. The shielding gasflows from in inner area of the neck 46 toward the welding nozzle 48 toshield the welding location from a surrounding atmosphere that may causeimperfections during a welding operation. The shielding gas flowsthrough gas-through ports 62 of the receiving assembly 58 upon exitingthe neck 46 to ultimately exit out of the welding nozzle 48 at thewelding location. The receiving assembly 58 may include pathways totransfer the shielding gas from the neck 46 to the gas-through ports 62,as described in detail in the discussion of FIGS. 8 and 9. Further, thereceiving assembly 58 may operate as a shielding gas diffuser.Accordingly, the receiving assembly 58 may direct the shielding gas inan axial direction 81 along an external portion of the contact tip 56while the contact tip 56 is in the fully secure position. Such directionof the shielding gas may aid in cooling the contact tip 56 during awelding operation.

Additionally, the wire (i.e., the electrode 18) is fed in the direction80 toward the welding location. The wire travels through the receivingassembly 58 and into the contact tip 56. The contact tip 56 includes anelongated body with a hollow interior 82. Further, the hollow interior82 receives the wire at an interface 84 with the receiving assembly 58and facilitates transmission of the wire in the direction 80 toward thewelding location. The interface 84 may include a space between a base(see, e.g., base portion 116 illustrated in FIG. 9) of the contact tip56 and the receiving assembly 58. That is, the base of the contact tip56 may maintain a small degree of separation from the receiving assembly58 at the interface 84.

FIG. 5 also provides an illustration of a path in which the current mayflow. For example, a coupling interface 86 couples to the neck 46 of thewelding torch 16 to the receiving assembly 58 via threaded regions 88 ofthe neck 46 and the coupling interface 86. Interaction between thethreaded regions 88 enables the flow of current from the neck 46 to thereceiving assembly 58. Upon entering the coupling interface 86, thecurrent travels to the inner bore 74 of the receiving assembly 58. Atthe inner bore 74, the current may have multiple transfer paths to thecontact tip 56. For example, the locking element 69 may be made from aconductive material (e.g., steel) enabling the flow of current throughthe locking element 69 into the contact tip 56, which is also made froma conductive material. Because, in the fully secure position, thelocking element 69 is in contact with both the receiving assembly 58 andthe contact tip 56, the flow of current may travel from the receivingassembly 58, through the locking element 69, and to the contact tip 56to produce the arc 24. Additionally, the contact tip 56 may receive theflow of current via a wall of the inner bore 74. As the flow of currententers the inner bore 74, the inner bore 74 is in contact with thecontact tip 56. Therefore, the flow of current may travel from the innerbore 74 directly to any portion of the contact tip 56 that is in contactwith the inner bore 74. As such, any one path described above, or anycombination of the paths, may provide sufficient contact for adequatecurrent transfer.

It may be appreciated that the coupling interface 86 may also enableretrofitting an existing welding torch with the receiving assembly 58,the contact tip 56, and the welding nozzle 48 disclosed herein. Forexample, the welding torch 16 may be sold with a traditional contact tipsecurement mechanism coupled to the neck 46 of the welding torch 16. Anoperator of the welding torch 16 may replace the traditional contact tipsecurement mechanism with the receiving assembly 58 described in thepresent disclosure. Accordingly, the operator may purchase the receivingassembly 58, the welding nozzle 48, and the contact tip 56 separatelyfrom the welding torch 16.

FIG. 5 also illustrates a mechanism for transitioning the contact tip 56between the fully secure position and the partially secure position. Asillustrated, the welding nozzle 48 is coupled to the receiving assembly58 establishing the fully secure position. Further, the welding nozzle48 is coupled to the receiving assembly 58 via the coupling interface 60of the receiving assembly 58 (e.g., threads 89) and threads 90 of thewelding nozzle 48. In the fully secure position, the locking element 69is urged into the retention groove 68 of the contact tip 56 by aninternal surface 92 of the welding nozzle 48 applying a linear force inthe axial direction 66 on the retention band 70. Movement in the axialdirection 66 may urge the retention band 70 toward a center of theradial orifice 72 and the locking element 69. Accordingly, the retentionband 70 may ride up an outer surface of the locking element 69 as theretention band 70 approaches the center of the radial orifice 72. Inthis manner, the retention band 70 applies continually greater pressureon the locking element 69 as the welding nozzle 48 is threaded onto thereceiving assembly 58. Therefore, the retention band 70 appliesadditional force on the locking element 69 into the retention groove 68in addition to the force already provided when the welding nozzle 48 isnot coupled to the receiving assembly 58. Additionally, the additionalforce on the locking element 69 may provide greater contact between thecontact tip 56 and the inner bore 74 for enhanced mechanical andelectrical coupling.

To transition the contact tip 56 to the partially secure position, thewelding nozzle 48 may be unscrewed from the receiving assembly 58 toremove the welding nozzle 48. Once the welding nozzle 48 is removed fromthe receiving assembly 58, the force applied by the welding nozzle 48onto the retention band 70 is also removed. Removing the force on theretention band 70 transitions the contact tip 56 to the partially secureposition. As discussed above, the contact tip 56 is removable withoutthe use of tools while in the partially secure position.

FIG. 6 is a cross-sectional illustration of a magnified portion of thewelding torch 16 illustrated in FIG. 5. The locking element 69 is urgedinto the retention groove 68 of the contact tip 56 by the internalsurface 92 of the welding nozzle 48 applying a linear force in the axialdirection 66 on the retention band 70. Movement in the axial direction66 may urge the retention band 70 toward a center of the radial orifice72 and the locking element 69. Accordingly, the retention band 70 mayride up an outer surface of the locking element 69 as the retention band70 approaches the center of the radial orifice 72 by moving in adirection 91. In this manner, the retention band 70 applies continuallygreater radially inward force on the locking element 69 as the weldingnozzle 48 is threaded onto the receiving assembly 58. Consequently, thelocking element 69 may move in a direction 93 into the retention groove68 as the welding nozzle 48 is secured to the welding torch 16.Therefore, the retention band 70 applies additional radially inwardforce on the locking element 69 into the retention groove 68 in additionto a radially inward force already provided when the welding nozzle 48is not coupled to the receiving assembly 58. Additionally, the addedradially inward force on the locking element 69 may provide greatercontact between the contact tip 56 and the inner bore 74 for enhancedmechanical and electrical coupling.

Further, FIG. 6 provides a detailed illustration of four components thatprovide the fully secure position of the contact tip 56. Namely, FIG. 6illustrates the receiving assembly 58, which receives the contact tip56; the locking element 69, which is seated within the radial orifice 72of the receiving assembly 58; the retention band 70, which provides aradially inward force on the locking element 69, and the welding nozzle48, which includes the internal surface 92 that urges the retention band70 toward the center of the radial orifice 72. As the welding nozzle 48is secured to the receiving assembly 58 via the threads 89 and 90, theinternal surface 92 provides the linear force in the axial direction 66on the retention band 70. The retention band 70 moves toward the centerof the radial orifice 72 and generates the radially inward force on thelocking element 69 toward the retention groove 68. Accordingly, thelocking element 69 is forced into the retention groove 68 to generatethe fully secure position of the contact tip 56 within the receivingassembly 58.

When the welding nozzle 48 is not secured to the receiving assembly 58,the retention band 70 may supply sufficient radially inward force on thelocking element 69 to maintain the locking element 69 within the radialorifice 72 and partially secured in the retention groove 68. However,without the welding nozzle 48 secured to the receiving assembly 58, aforce provided toollessly on the contact tip 56 in the axial direction81 may be sufficient to remove the contact tip 56 from the receivingassembly 58. For example, a lip 95 of the retention groove 68 mayprovide a radially outward force on the locking element 69 when theforce is provided on the contact tip 56 in the axial direction 81. Theradially outward force may elastically deform the retention band 70sufficiently for the locking element 69 to exit the retention groove 68,as the contact tip 56 is removed from the receiving assembly 58 in theaxial direction 81.

FIG. 7 is a flow diagram of a method 94 for installing the contact tip56 in the fully secure position. Initially, at block 96, with thewelding nozzle 48 uncoupled from the receiver assembly 58, an axialforce is applied on the contact tip 56 in the axial direction 66 towardthe neck 46 of the welding torch 16 and into the inner bore 74. Theamount of axial force that establishes the partially secure position maybe a force sufficient to overcome the radially inward force exerted bythe retention band 70 on the locking element 69 toward the inner bore 74of the receiving assembly 58. The axial force provided on the contacttip 56 in the axial direction 66 may be substantially perpendicular tothe radially inward force exerted on the locking element 69.Accordingly, the contact tip 56 may be established in the partiallysecure position without the use of tools.

Subsequently, at block 98, the welding nozzle 48 is installed over thecontact tip 56 and the receiving assembly 58. As discussed above, thewelding nozzle 48 provides additional radially inward force on thelocking element 69 to aid in establishing the fully secure position ofthe contact tip 56. Additionally, the welding nozzle 48 may provide theadditional radially inward force with the internal surface 92interacting with the retention band 70. As the welding nozzle 48 movesfurther down the receiving assembly 58 in the axial direction 66, thelocking element 69 experiences more radially inward force toward theretaining groove 68 of the contact tip 56.

Further, at block 100, the welding nozzle 48 is secured to the receivingassembly 58. The welding nozzle 48 may be secured to the receivingassembly 58 via the coupling interface 60 of the receiving assembly 58,which may include threads 89, and the threads 90 of the welding nozzle48. Accordingly, the welding nozzle 48 may be threaded onto thereceiving assembly 58 until the welding nozzle 48 reaches the end of thethreads 89 of the coupling interface 60. At this position, the weldingnozzle 48 may be secured to the welding torch 16, and the contact tip 56may be in a fully secured position within the receiving assembly 58.Additionally, the welding nozzle 48 may be secured to the receivingassembly 58 without the use of tools. Further, the welding nozzle 48 maybe secured to the receiving assembly 58 in any other suitable mannerthat may establish a similar force on the locking element 69 into theretention groove 68.

FIG. 8 is a perspective view of the welding torch 16 with an end portionof the receiving assembly 58 and the contact tip 56 removed. In thismanner, contact tip cooling channels 110 are illustrated surrounding thecontact tip 56. The contact tip cooling channels 110 may be orthogonalto portions of the inner bore 74 of the receiving assembly 58 upon whichthe contact tip 56 is secured, as described herein.

Further, the contact tip cooling channels 110 may direct a flow ofshielding gas along an axial length of the contact tip 56 within theinner bore 74 of the receiving assembly 58 (e.g., between the contacttip 56 and the receiving assembly 58 within the contact tip coolingchannels 110). The flow of shielding gas along the axial length of thecontact tip 56 provides a heat transfer medium for the contact tip 56during a welding operation. Accordingly, heat generated at the contacttip 56 may be transferred to the shielding gas as the shielding gasflows along the contact tip 56 and exits the welding torch 16 toward thework piece 26. The transfer of heat to the shielding gas may result inthe contact tip 56 operating at a lower temperature. Additionally, thelower temperature may decrease wear on the contact tip 56 and increaselongevity of the contact tip 56.

FIG. 9 is a cross-sectional illustration of the receiving assembly 58and the contact tip 56 including the contact tip cooling channels 110.The cross-sectional illustration provides a more detailed view of thecooling channels 110 and an interaction of portions of the contact tip56 within the receiving assembly 58. For example, the contact tip 56 maybe in contact with the inner-bore 74 of the receiving assembly 58 forless than 50 percent of the surface area of a portion of the contact tip56 disposed within the receiving assembly 58. The portions in contactwith the inner-bore 74 provide an adequate surface area to secure thecontact tip 56 within the receiving assembly 58. Further, the coolingchannels 110, which may abut greater than 50 percent of the surface areaof the contact tip 56 within the receiving assembly 58, provide adequateheat transfer between the flow of shielding gas and the contact tip 56to reduce an operating temperature of the contact tip 56 during awelding operation.

FIG. 10 is a cross-sectional illustration of a portion of the contacttip 56 including a gas flow path 112 along the axial length of thecontact tip 56. The shielding gas may travel along the gas flow path 112from the neck 46 of the welding torch 16 along a weld cable liner 114.After exiting the neck 46, the shielding gas may travel through thecontact tip cooling channels 110 (e.g., between an outer surface of thecontact tip 56 and an inner surface of the receiving assembly 58)andradially out the gas-through ports 62 of the receiving assembly 58. Asdiscussed above, as the shielding gas traverses the contact tip coolingchannels 110 (e.g., axially flowing in the general direction of thecentral axis 108 of the welding torch 16), heat generated at a baseportion 116 of the contact tip 56 during a welding operation maytransfer to the shielding gas moving along the gas flow path 112. Thismay result in reduced temperatures at which the contact tip 56 operates.Additionally, the base portion 116 of the contact tip 56 may include aportion of the contact tip 56 that is received within the inner bore 74of the receiving assembly 58.

After exiting through the gas-through ports 62 (e.g., in a radialdirection generally perpendicular to the central axis 108), theshielding gas may be directed by the welding nozzle 48 away from thewelding torch 16 and toward the work piece 26. As the shielding gastravels within the welding nozzle 48 after exiting the gas-through ports62, an upper portion 118 of the contact tip 56 may transfer additionalheat to the shielding gas as the shielding gas flows toward the workpiece 26 along the gas flow path 112.

It may be appreciated that while FIGS. 8-10 of the present disclosureillustrate two of the contact tip cooling channels 110 formed betweenthe contact tip 56 and the receiving assembly 58, one or more of thecontact tip cooling channels 110 of the receiving assembly 58 may beformed around the contact tip 56 during actual implementation of thecontact tip cooling channels 110. For example, the receiving assembly 58may include one, two, three, or more of the contact tip cooling channels110 depending on the configuration of the receiving assembly 58.

Further, the contact tip cooling channels 110 cumulatively may providecontact between greater than half of a surface area of the base portion116 of the contact tip 56 and the shielding gas. For example, portionsof the inner bore 74 of the receiving assembly 58 that are in contactwith the contact tip 56 to provide partial and full securement of thecontact tip 56 within the receiving assembly 58 may include less thanhalf of the surface area of the base portion 116. Alternatively, in someembodiments, the portions of the inner bore 74 that are in contact withthe contact tip 56 to provide partial and full securement of the contacttip 56 within the receiving assembly 58 may include greater than half ofthe surface area of the base portion 116. Accordingly, in variousembodiments, the portions of the inner bore 74 of the receiving assembly58 that are in contact with the contact tip 56 may contact between 20and 80 percent of the surface area of the base portion 116 of thecontact tip 56 while still maintaining the contact tip 56 in a partiallyor fully secured position within the receiving assembly 58.

While only certain features of the subject matter have been illustratedand described herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the disclosure.

1. A method to secure a contact tip in a welding system, comprising:applying an axial force on the contact tip toward a receiving assemblyof a welding torch to establish a partially secure coupling of thecontact tip to the receiving assembly; and securing a welding nozzle tothe receiving assembly to establish a fully secure coupling of thecontact tip to the receiving assembly.
 2. The method of claim 1, whereinthe receiving assembly is configured to retrofit and replace an existingcontact tip mechanism of the welding torch.
 3. The method of claim 1,wherein applying the axial force and securing the welding nozzle isaccomplished without the use of tools.
 4. The method of claim 1, whereinestablishing the partially secure coupling comprises seating a lockingelement of the receiving assembly within a retention groove of thecontact tip.
 5. The method of claim 1, wherein the contact tip istoollessly removable after the partially secure coupling is established.6. The method of claim 1, wherein the contact tip is not toollesslyremovable after the fully secure coupling is established.
 7. The methodof claim 1, wherein the receiving assembly comprises a locking elementthat establishes the partially secure coupling, and the welding nozzleprovides a force on the locking element that establishes the fullysecure coupling.
 8. The method of claim 1, comprising removing thewelding nozzle from the receiving assembly to reestablish the partiallysecure coupling of the contact tip and the receiving assembly.
 9. Themethod of claim 1, wherein securing the welding nozzle to the receivingassembly comprises threading the welding nozzle onto the receivingassembly without the use of tools.
 10. A welding torch systemcomprising: a receiving assembly configured to receive a contact tip anda welding nozzle; a locking element configured to retain the contact tipin a partially secure position; and the welding nozzle configured tocouple to the receiving assembly to retain the contact tip in a fullysecure position.
 11. The welding torch system of claim 10, wherein thecontact tip is toollessly removable from the receiving assembly when thecontact tip is in the partially secure position.
 12. The welding torchsystem of claim 10, wherein the contact tip is not toollessly removablefrom the receiving assembly when the contact tip is in the fully secureposition.
 13. The welding torch system of claim 10, wherein the lockingelement comprises a locking element positioned within a radial orificeof the receiving assembly.
 14. The welding torch system of claim 10,comprising a retention band disposed around the receiving assembly,wherein the retention band is configured to provide a first force on thelocking element to establish the partially secure position of thecontact tip.
 15. The welding torch system of claim 14, wherein thewelding nozzle is configured to provide a second force on the retentionband while the welding nozzle is coupled to the receiving assembly toestablish the fully secure position of the contact tip.
 16. A torchsystem comprising: a contact tip configured to mount without toolswithin a receiving assembly mounted on a welding torch, wherein thecontact tip is configured to transition between a fully secured positionand a partially secured position within the receiving assembly, andwherein the contact tip comprises an elongated hollow body comprising anelectrically conductive material, wherein the elongated hollow body isconfigured to interact with a locking element of the receiving assembly.17. The torch system of claim 16, wherein the contact tip comprises aretention groove disposed on an outer surface of the elongated hollowbody near an axial end of the elongated hollow body, wherein theretention groove is configured to receive the locking element of thereceiving assembly.
 18. The torch system of claim 16, wherein thecontact tip comprises one or more discrete recesses surrounding theelongated hollow body near an axial end of the elongated hollow body,wherein the one or more discrete recesses surrounding the elongatedhollow body are configured to receive the locking element of thereceiving assembly.
 19. The torch system of claim 16, wherein thelocking element is configured to retain the contact tip within thereceiving assembly.
 20. The torch system of claim 16, wherein thecontact tip is in the fully secured position when a welding nozzle iscoupled to the receiving assembly, and the contact tip is in thepartially secured position when the welding nozzle is not coupled to thereceiving assembly.
 21. The torch system of claim 20, wherein thewelding nozzle interacts with a retention band to provide additionalforce on the locking element to establish the fully secured position ofthe contact tip.
 22. The torch system of claim 16, wherein a firstdiameter of the contact tip is 98 percent of a second diameter of aninner bore of the receiving assembly.